CA1198488A - Coaxial cables - Google Patents

Coaxial cables

Info

Publication number
CA1198488A
CA1198488A CA000423535A CA423535A CA1198488A CA 1198488 A CA1198488 A CA 1198488A CA 000423535 A CA000423535 A CA 000423535A CA 423535 A CA423535 A CA 423535A CA 1198488 A CA1198488 A CA 1198488A
Authority
CA
Canada
Prior art keywords
layer
coaxial cable
filaments
polymeric
circumferentially
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000423535A
Other languages
French (fr)
Inventor
Richard E. Hawkins
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Champlain Cable Corp
Original Assignee
Champlain Cable Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Champlain Cable Corp filed Critical Champlain Cable Corp
Application granted granted Critical
Publication of CA1198488A publication Critical patent/CA1198488A/en
Expired legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00Communication cables or conductors
    • H01B11/18Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/1834Construction of the insulation between the conductors

Abstract

COAXIAL CABLES

Abstract of the Disclosure A dielectric system for coaxial electrical conductors is provided. The dielectric system separates an inner and outer conductor and is composed of a first layer of braided high tensile strength polymeric fluorocarbon filaments in an open weave surrounding the inner conductor. Surrounding the layer of braided filaments is a continuous layer of a poly-meric film which is in turn surrounded by a continuous layer of a crosslinkable polymeric lacquer enclosing both the layer of braided filaments and the layer of polymeric film.

Description

The present invention relates to a dielectric system for use in a coaxial cable. In particular, the present invention relates to a dielectric syst~m for coaxial electrical conduc-tors which separates an inner and an outer conductive mater-ial and which comprises a first layer of braided high tensilestrength polymeric fluorocarbon filaments in an open weave surrounding an inner conductor along its length, a second layer overlying the braided filament layer consisting of a continuous skin of polymeric film, and a third layer over-lying the second layer consisting of a continuous skin ofcrosslinkable polymeric lacquer.
A coaxial cable is usually comprised of an inner conduc-tive member, a dielectric system surrounding the inner con-ductor, and an outer conductive member coaxially surrounding the dielectric system. The inner conductive member and the outer conductive members are made with some appropriate metal, most commonly copper, aluminum or some alloy containing such metal. The dielectric system i5 usually composed of some suitable plastic, and use of polyethylene, polystyrene, and polypropylene, in expanded or une~panded form, is common.
The best dielectric, from a theoretical standpoint, would be a layer of air, which has a dielectric constant of lØ It is virtually impossible to construct such a cable, however, and commercial cables employ solid materials with necessarily higher dielectric constants. ~he higher the dielectric constant of the material, the lower the velocity of propagation of the coaxial cable as a whole, and thus, the longer the cable will take to transmit an electrical signal along its length. In addition to improved velocity of propa-gation, a lower dielectric constant will allow a thinner ~98488 insulation l~yer which should produce a smaller finished cablediameter. This becomes important in applications which have space or weight limitations.
One method which has been followed in attempting to increase the velocity of propagation of a cable has been to decrease the effective dielectric constant by introducing air or other materials into an otherwise solid dielectric layer.
In United ~tates Patent 3,309,458, a coaxial conductor is shown which employs as a dielectric a two-layer system.
The first layer of the system is comprised of a hrittle foamed synthetic resin and the second layer is composed of a non-foamed synthetic resin which is pliable in comparison with the foamed resin.
In United States Patent 3,573,976, a coaxial cable is provided in which the dielectric is extruded from a combina~
tion of glass, silica or ceramic microspheres; a suspension of powdered polyethylene or polymeric fluorocarbon resin; a volatile ethylene dichloride or trichloroethylene carrier and a ta~kifying agent of polyisobutylene or hexafluoropropylene-vinylidene fluoride copolymer. The microspheres, or micro-balloons as they are also known, are discrete, hollow, spher-ical particles, and the effective dielectric constant of the dielectric system is reduced according to the amount of air encapsulated therein.
United States Patent 3,968,463 discloses a coaxial cable having as a dielectric coating on the core conductor, an extruded cellular ethylene or propylene polymer based compo-sition.
United States Patent 4j107,354 is directed to a method of forming a coaxial cable by coating a center conductor of the cable with a dielectric composed of cellular polyolefin.
The problem which has been encountered with coaxial cables employing foamed dielectric systems is that as the amount of foaming, and therefore the amount of encapsulated air, is increased, the mechanical and heat resistance pro-perties of the cable are adversely affected. To provide sufficient mechanical strength, cables must have diminished ~8~38 flexibility or increased size, and this limits the applications for which the cable may be used.
Another method used to incorporate air into the dielec-tric system has been through the use of disk type insulating separators. Following this method, disk type insulating separators of a material such as polyethylene are fitted onto an inner con-ductor at spaced intervals, thereby leaving air filled interstitial spaces. Such construction, however, lacks mechanical strength, particularly when the coaxial cable is bent, and the cables must be handled with great care.
According to the present invention, there is provided a coaxial cable having improved strength properties over a wide temperature range, comprising: (a) an inner conductor; (b) a dielectric structure comprising: (1) a first layer of braided high tensile strength polymeric fluorocarbon filaments surrounding said inner conductor in an open weave along the length of the inner conductor, said filaments having a tensile strength of at least 40,000 psi and a dielectric constant of less than 2.8;
(ii) a second layer consisting of a polymeric film surrounding circumferentially the first layer and providing a continuous skin enclosing the first layer; and (iii) a third layer consisting of a crosslinked polymeric lacquer surrounding circumferentially the second layer and providing a continuous skin enclosing the second layer; (c) an outer conductor disposed circumferentially about the dielectric system; and (d) an outer protective layer surrounding circumferentially the outer conductor.
The drawing shows a segment of a coaxial cable with the dielectric system of the present invention, having the various ~98~88 layers cut away for the purposes of illustration.
A typical coaxial conduc~or employing the dielectric system (19) of the present invention is shown in the drawing.
The coaxial cable (10) has been cut away to show its various layers.
An inner metallic conductor (12), sometimes referred to as a core~
is shown as the central element, and is surrounded circumferentially by the dielectric system (19) of the present invention. This conductor may be constructed of copper or aluminum or some appropriate alloy, and may be in the form of a solid wire or a plurality of individual metallic strands wound together.
This inner conductor (12) is surrounded by a first layer of braided high tensile strength polymeric fluorocarbon filaments which create an open weave (14) about the said inner conductor (12).
These filaments should have a tensile strength of at least 40,000 p.s.i., preferably in the range of 45,000 to 55,000 p.s.i., and they should have a dielectric constant of less than 2.8. A suitable material for the filaments is an ethylene-chlorotrifluoroethylene copolymer. A continuous layer (16) which may be composed of polyimide, polyparabanic acid, polyester or any similar thin, high tensile strength polymeric film which remains stable at temperatures up to 150C. This polymeric film provides a continuous skin surrounding the layer of braided filaments (14) and helps to encapsulate air in the open weave of the braided filaments (14).
It is advantageous to apply this layer in a solid form so as not to infiltrate the interstices of the braided layer in the place of the desired air. For this reason, the present invention contemplates the application of the material for this layer in the form of a ~198~8 continuous tape wrapped around the braided layer (14) by means well known to the art. However, the present invention is not meant to be limited to the application of this layer (16) by this means.
A continuous layer of crosslinkable polymeric lacquer (18) surrounds the polymeric film (16) and acts both as an adhesive, holding the inner layers in place, and as a sealant.
This layer (18) represents the outermost layer of the dielectric system (19) of the present invention and may be applied by a dip coating technique or by other means known to the art. A preferred crosslinkable polymeric lacquer is a lacquer of methyl methacrylate.
To complete the cable, an outer conductor (20), which may be woven or solid, is disposed circumferentially about the dielectric system (19) of the present invention and said outer conductor (20) is typically surrounded circumferentially by a compatible protective layer (22) of a type well known to the art.
Example 1 A small diameter coaxial cable for use in an application requiring miniature coaxial cable was fabricated with the dielectric system of the present invention in the following manner. A 30 AWG
solid copper conductor with a 0.010 inch diameter was used as a central conductive member. Eight 0.005 inch filaments of ethylene-chlorotrifluoroethylene copolymer, - 4a -~ 98488 available commercially from Allied Chemical under the Trade-mark Hala ~ were braided over said central conductor on a Wardwell Braiding Machine Company sixteen carrier braider to a density of 10 to 15 picks per inch.
Over the open weave braid thus produced, a layer of poly-parabanic acid, commercially available from Exxon under the Trademark Tradlo ~ was applied. ~he polyparabanic acid was applied in the form of a thin tape, .001 inch in thickness and .125 inch in width, on an EJR Engineering tape-wrapping machine which is capable of providing accurate tension con-trol. The tape was applied with a sufficient overlap, about 25%, to avoid separation when the cable is bent while still maintaining a small diameter in the dielectric system.
Over the polyparabanic acid layer, an acrylic topcoat layer was applied which acts as an adhesive and sealant. In this example, a thin coating of liquid methyl methacrylate containing a self-contained crosslinking agent, commercially available from the Rohm and Haas Company under the Trademark Rhoplex AC-123 ~ was applied using a dip flow coating tech-nique known to the art, and cured in a wire enameling oven.An outer conductive member and a protective layer of polymeric fluorocarbon were applied in a manner well known to the art.
The resulting cable demonstrated the following useful properties, which did not deteriorate with substantial hand-ling or flexing and exposure to a wide temperature range.
Electrical:
Characteristic Impedance: approximately 55 ohms Capacitance: 22-23 picofarads per foot Velocity of Propagation: approximately 80% (of the speed of light).
Other:
Finished cable diameter: less than .060 inch Maximum continuous operating temperature: in the 150C.
range Flexibility and mechanical strength: very good Solder bath test (230~C. - 15 sec.): no effect.
Example 2 A small diameter coaxial cable was fabricated according 119848~

to the method described in Example 1. A 30 A~IG central con ductive member comprised of seven copper strands and having a combined diameter of .012 inch was braided over to a braid density of 10 to 15 picks per inch with eight filaments of ethylene-chlorotrifluoroethylene copolymer. Each said fila-ment had a diameter in the range of .009 to .010 inch. A
continuous layer of polyparabanic acid was then applied over the open weave of the braided layer following the teachings of E~ample 1, and using a polyparabanic acid tape .001 inch in thic~ness and .187 inch in width in such a manner so as to produce a 20-25 percent overlap. An acrylic topcoat layer of the same material used in Example 1 was applied in the same manner as described therein. Following this, an outer con-ductive member and a protective layer were applied in a manner well known to the art.
lhe resulting cable had a characteristic impedance of 75 ohms and demonstrated useful dielectric properties.
Example 3 A small diameter coaxial cable was fabricated according to the method described in Example 1. A 32 AWG solid copper central conductive member having a .008 inch diameter was braided over to a braid density of 10-15 picks per inch with eight filaments of ethylene-chlorotrifluoroethylene copoly-mer. Each said filament had a diameter in the range of .009 to .010 inch. A continuous layer of polyparabanic acid was then applied over thé open weave of the braided layer follow-ing the teachings of Example 1, using a polyparabanic acid tape .001 inch in thickness and .187 inch in width in such a manner so as to produce a 20-25 percent overlap. An acrylic topcoat layer of the same material used in Example 1 was applied in the same manner as described therein. Following this, an outer conductive member and a protective layer were applied in a manner well known to the art.
The resulting cable had a characteristic impedance of 90 ohms and demonstrated useful dielectric properties.

Claims (11)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
1. A coaxial cable having improved strength properties over a wide temperature range, comprising: (a) an inner con-ductor; (b) a dielectric structure comprising: (1) a first layer of braided high tensile strength polymeric fluorocarbon filaments surrounding said inner conductor in an open weave along the length of the inner conductor, said filaments having a tensile strength of at least 40,000 psi and a dielectric constant of less than 2.8; (ii) a second layer consisting of a polymeric film surrounding circumferentially the first layer and providing a continuous skin enclosing the first layer; and (iii) a third layer consisting of a crosslinked polymeric lacquer surrounding circumferentially the second layer and providing a continuous skin enclosing the second layer; (c) an outer conductor disposed circumferentially about the dielec-tric system; and (d) an outer protective layer surrounding circumferentially the outer conductor.
2. A coaxial cable of claim 1 in which the second layer of polymeric film of the dielectric system is a polymeric film which remains stable at temperatures of up to 150°C., said polymeric film being applied in the form of a tape helically wrapped about said first layer.
3. A coaxial cable of claim 2 in which the second layer of polymeric film is polyparabanic acid film.
4. A coaxial cable of claim 2 in which the second layer of polymeric film is a polyimide film.
5. A coaxial cable of claim 2 in which the second layer of polymeric film is a polyester film.
6. A coaxial cable of claim 3 in which the third layer is a crosslinked polymer of methyl methacrylate.
7. A coaxial cable of claim 4 in which the third layer is a crosslinked polymer of methyl methacrylate.
8. A coaxial cable of claim 5 in which the third layer is a crosslinked polymer of methyl methacrylate.
9. A coaxial cable of claim 3, 4 or 5 wherein the high tensile strength polymeric fluorocarbon filaments are filaments of an ethylene-chlorotrifluoroethylene copolymer.
10. A coaxial cable of claim 6, 7 or 8 wherein the high tensile strength polymeric fluorocarbon filaments are filaments of an ethylene-chlorotrifluoroethylene copolymer.
11. A method of making a coaxial cable having improved strength properties over a wide temperature range, comprising:
(a) covering a metallic conductor circumferentially with a first layer of braided high tensile strength polymeric fluorocarbon filaments in an open weave along the length of the conductor, said filaments having a tensile strength of at least 40,000 psi and a dielectric constant of less than 2.8; (b) covering the first layer circumferentially with a second layer of a polymeric film thereby providing a continuous skin enclosing the first layer;
(c) covering the second layer circumferentially with a third layer consisting of a crosslinked polymeric lacquer thereby providing a continuous skin enclosing the second layer; (d) covering the third layer circumferentially with an outer conductor; and (e) covering the outer conductor circumferentially with an outer protective layer.
CA000423535A 1982-03-17 1983-03-14 Coaxial cables Expired CA1198488A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US358,955 1982-03-17
US06/358,955 US4440973A (en) 1980-06-05 1982-03-17 Coaxial cables

Publications (1)

Publication Number Publication Date
CA1198488A true CA1198488A (en) 1985-12-24

Family

ID=23411712

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000423535A Expired CA1198488A (en) 1982-03-17 1983-03-14 Coaxial cables

Country Status (6)

Country Link
US (1) US4440973A (en)
EP (1) EP0089226B1 (en)
JP (1) JPS58169811A (en)
CA (1) CA1198488A (en)
DE (1) DE3373160D1 (en)
IL (1) IL68039A (en)

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JPS6291311U (en) * 1985-11-27 1987-06-11
GB2374721B (en) * 1986-05-17 2003-02-26 Stc Plc Coaxial cable
US5025115A (en) * 1990-05-22 1991-06-18 W. L. Gore & Associates, Inc. Insulated power cables
US5158086A (en) * 1990-07-20 1992-10-27 W. L. Gore & Associates, Inc. Invasive probe system
US5171635A (en) * 1990-10-10 1992-12-15 E. I. Du Pont De Nemours And Company Composite wire construction
US5293442A (en) * 1992-07-15 1994-03-08 W. L. Gore & Associates, Inc. Crush-resistant high-strength buffered optical waveguide fiber cable
DE19703437A1 (en) * 1997-01-30 1998-08-06 Luitpold Pharma Gmbh Mixtures of outer membranes and / or cell walls of bacteria for oral immunization against mucosal infections
US6294455B1 (en) 1997-08-20 2001-09-25 Micron Technology, Inc. Conductive lines, coaxial lines, integrated circuitry, and methods of forming conductive lines, coaxial lines, and integrated circuitry
US6143616A (en) 1997-08-22 2000-11-07 Micron Technology, Inc. Methods of forming coaxial integrated circuitry interconnect lines
US6187677B1 (en) 1997-08-22 2001-02-13 Micron Technology, Inc. Integrated circuitry and methods of forming integrated circuitry
GB0006333D0 (en) * 2000-03-16 2000-05-03 Raychem Ltd Electrical wire insulation
JP4020382B2 (en) * 2000-11-06 2007-12-12 電気化学工業株式会社 Conductive polypropylene resin foam sheet and container
EP1585144A3 (en) * 2004-04-08 2006-02-08 ERNST & ENGBRING GmbH & Co. KG Cable and audio cable assembly
US7754969B2 (en) * 2007-06-08 2010-07-13 Southwire Company Armored cable with integral support
CN104282365A (en) * 2014-05-13 2015-01-14 山东无棣海丰电缆有限公司 Warping-resistant and stretching-resistant multi-purpose braided cable
MX2017016979A (en) * 2017-12-20 2019-06-21 Servicios Condumex Sa Coaxial cable resistant to contraction caused by temperature changes.

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US4332976A (en) * 1980-06-05 1982-06-01 Champiain Cable Corporation Coaxial cables
US4340773A (en) * 1980-06-13 1982-07-20 Champlain Cable Corporation Coaxial cables with foam dielectric

Also Published As

Publication number Publication date
EP0089226A2 (en) 1983-09-21
JPS58169811A (en) 1983-10-06
IL68039A0 (en) 1983-06-15
EP0089226A3 (en) 1984-07-04
IL68039A (en) 1987-03-31
US4440973A (en) 1984-04-03
EP0089226B1 (en) 1987-08-19
DE3373160D1 (en) 1987-09-24

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